In-ear audio device customization

ABSTRACT

An in-ear audio device has a casing on which is disposed one or more bags are positioned to be filled with fillable material during a customization process in which a test sound is acoustically output into an ear canal by an acoustic driver of the in-ear audio device while the one or more bags are being filled, and a microphone acoustically coupled to the ear canal is employed to detect sounds within the ear canal that are indicative of the frequency response of the acoustic output of the acoustic driver to determine when the degree of sealing of the ear canal by the one or more bags is sufficient to achieve a desired quality of frequency response.

TECHNICAL FIELD

This disclosure relates to customizing the fit of an in-ear audio devicewithin a portion of an ear.

BACKGROUND

The use of audio devices structured to be at least partly inserted intoone or both ears of a user (i.e., so called “in-ear” audio devices or“intra-aural” audio devices) to enable audio to be acoustically outputto one or both ears of a user has become commonplace, especially withthe widespread use of digital audio recording playback devices (e.g.,MP3 digital file players) and two-way wireless communications devices(e.g., cell phones and personal data assistant devices incorporatingcell phone capabilities). However, difficulties remain in providingin-ear audio devices that fit comfortably in users' ears, and that fitwell enough to cooperate with the structure of the ear to provide a highquality of sound in the acoustic output of audio. Much of the reason forthis difficulty is that no two ears have shapes that are ever exactlyalike, such that an in-ear audio device that is able to provide a goodfit in an ear of one user may be unable to do so in an ear of anotheruser.

One well known solution is to provide in-ear audio devices with aselection of removable hollow ear couplings that are each shaped and/orsized differently to enable the in-ear audio devices to be used withdifferent dimensions and shapes of ears. However, as is well-known tothe users of in-ear devices, achieving a good fit can be difficult evenwith in-ear audio devices that are supplied with a relatively extensiveassortment of hollow ear couplings from which to choose.

SUMMARY

An in-ear audio device has a casing on which is disposed one or morebags are positioned to be filled with fillable material during acustomization process in which a test sound is acoustically output intoan ear canal by an acoustic driver of the in-ear audio device while theone or more bags are being filled, and a microphone acoustically coupledto the ear canal is employed to detect sounds within the ear canal thatare indicative of the frequency response of the acoustic output of theacoustic driver to determine when the degree of sealing of the ear canalby the one or more bags is sufficient to achieve a desired quality offrequency response.

In one aspect, an apparatus includes: a casing shaped to fit into aportion of an ear, the casing comprising a bag fillable with a fillingmaterial to customize the fit of the casing within the portion of theear to create a seal between the casing and the portion of the ear thatacoustically separates an ear canal of an ear from an externalenvironment that is external to the ear and casing; an acoustic driverdisposed within the casing to acoustically output a test sound into theear canal; and at least one aperture formed in the casing to permit aportion of a microphone to be inserted therethrough from the externalenvironment external and into the ear canal to acoustically couple themicrophone to the ear canal.

The casing may further include structure forms an open interior portionwithin the casing that is interposed between the ear canal and theexternal environment, and that separates the open interior portion fromthe ear canal and the external environment. Also, the at least oneaperture formed in the casing may include both a first aperture couplingthe open interior portion to the external environment and a secondaperture coupling the open interior portion to the ear canal, where thefirst and second apertures are sufficiently aligned to enable theportion of the microphone to be inserted through both the first andsecond apertures.

In another aspect, a method of customizing the fit of a portion of acasing of an in-ear audio device within a portion of an ear includes:driving an acoustic driver of the in-ear audio device to acousticallyoutput a test sound into the ear canal of the ear; monitoring amicrophone that is acoustically coupled to the ear canal to detectsounds within the ear canal that are indicative of the frequencyresponse of the acoustic driver acoustically outputting the test soundinto the ear canal; filling a bag of the casing with a filling materialas the acoustic driver is driven to acoustically output the test soundand the microphone is monitored; and employing the sounds detected bythe microphone that are indicative of the frequency response of theacoustic driver acoustically outputting the test sound into the earcanal to determine if a degree of sealing between the portion of thecasing and the portion of the ear achieves a desired quality offrequency response of the acoustic driver acoustically outputting thetest sound.

In still another aspect, an apparatus includes: a filling control tocontrollably convey filling material into a first tube structured to becoupled to a bag of a casing of an in-ear audio device; an earpieceinterface to at least signal the in-ear audio device with a test soundto be acoustically output by an acoustic driver disposed within thecasing of the in-ear audio device; a processing device; and a storagestoring a sequence of instructions. When the sequence of instructions isexecuted by the processing device, the processing device is caused to:operate the earpiece interface to cause the acoustic driver toacoustically output the test sound into an ear canal of an ear; monitora microphone that is acoustically coupled to the ear canal to detectsounds within the ear canal that are indicative of the frequencyresponse of the acoustic driver acoustically outputting the test soundinto the ear canal; operate the filling control to fill the bag with thefilling material as the acoustic driver is driven to acoustically outputthe test sound and the microphone is monitored; and employ the soundsdetected by the microphone that are indicative of the frequency responseof the acoustic driver acoustically outputting the test sound into theear canal to determine if a degree of sealing between the portion of thecasing and the portion of the ear achieves a desired quality offrequency response of the acoustic driver acoustically outputting thetest sound.

In each of these above aspects, the test sound may include a wide rangeof frequencies of human audible sounds or a lower human audiblefrequency.

Other features and advantages of the invention will be apparent from thedescription and claims that follow.

DESCRIPTION OF THE DRAWINGS

FIGS. 1a and 1b are perspective views of a embodiment of in-ear audiodevice.

FIGS. 2a and 2b are perspective views of another embodiment of in-earaudio device.

FIGS. 3a and 3b are partially cutaway views of variants of theembodiment of in-ear audio device of FIGS. 1a and 1b prepared forcustomization of fit into portions of a user's ear.

FIG. 4 is block diagram of a customization system usable with any of theembodiments or variants of embodiments of in-ear audio device depictedin any of the above figures.

DETAILED DESCRIPTION

What is disclosed and what is claimed herein is intended to beapplicable to a wide variety of in-ear audio devices, i.e., devices thatare structured to be used in a manner in which at least a portion of thedevice is positioned within the concha and/or ear canal portions of anear of a user. It should be noted that although specific embodiments ofan in-ear audio device primarily serving the purpose of acousticallyoutputting audio are presented with some degree of detail, suchpresentations of specific embodiments are intended to facilitateunderstanding through provision of examples, and should not be taken aslimiting either the scope of disclosure or the scope of claim coverage.

It is intended that what is disclosed and what is claimed herein isapplicable to in-ear audio devices that either do or do not supporttwo-way communications, and either do or do not support active noisereduction (ANR). In the case of in-ear audio devices that do supporteither two-way communications or ANR, it is intended that what isdisclosed and claimed herein is applicable to an in-ear audio deviceincorporating one or more microphones disposed on a portion of thein-ear audio device that remains outside an ear when in use, on aportion that is inserted into a portion of an ear when in use, ordisposed on both of such portions. Still other implementations of in-earaudio devices to which what is disclosed and what is claimed herein isapplicable will be apparent to those skilled in the art.

FIGS. 1a and 1b, taken together, provide two views of one embodiment ofan in-ear audio device 100 having a casing made up of at least a canalportion 110 meant to be positioned within an ear canal of a user's earand a concha portion 120 meant to be positioned within the concha of theuser's ear. More specifically and as depicted, the concha portion 120has a generally C-shaped configuration to substantially fill the conchaof a user's ear while accommodating the complex shape of the concha asdefined by portions of the tragus, anti-tragus, helix and anti-helix ofthe pinna of the ear. This C-shaped configuration has a pair ofextensions 122 and defines an inset curve 123 to accommodate the partialprotrusion of a portion of the helix into the concha. The canal portion110 has a generally tubular shape extending from where one end of thecanal portion 110 is coupled to the concha portion 120 at a locationcoincident with where the entrance to the ear canal is typically locatedin relation to the portion of the concha defined by portions of thetragus and anti-tragus. An aperture 118 is formed in the other end ofthe canal portion 110 to enable sounds to be acoustically output by anacoustic driver (not shown) positioned within the casing of the in-earaudio device 100 through the aperture 118 and into the ear canal whenthe in-ear audio device 100 is properly positioned in the user's earduring operation.

This embodiment of the in-ear audio device 100 depicted in FIGS. 1a-bmay be any of a variety of types of in-ear audio device able to performany of a variety of audio functions, including and not limited to, anin-ear earphone to acoustically output audio, an in-ear ANR device toprovide a reduction in environmental noise sounds encountered by a userthrough the acoustic output of anti-noise sounds, and/or a two-way audiocommunications audio device employing detection of the user's speechsounds through bone conduction and/or a Eustachian tube connected toportions of the ear into which the in-ear audio device 100 is inserted.Further, it should be noted that although the concha portion 120 hasbeen depicted and described as having a C-shaped configuration tosubstantially fill the concha, other embodiments are possible having asomewhat differently shaped concha portion 120 that does not fill asmuch of the concha. As will later be described in considerable detail,one or both of the canal portion 110 and the concha portion 120 is atleast partly surrounded by one or more fitting bags (not shown) able tobe filled with a filling material to customize the fit of the in-earaudio device 100 in the ear canal and/or the concha, respectively, of auser's ear.

Also, although not specifically depicted, the in-ear audio device 100may further incorporate an electrically and/or optically conductivecable to enable the in-ear audio device 100 to at least receive audio tobe acoustically output by the in-ear audio device 100 from another audiodevice (not shown) to which the in-ear audio device 100 is coupled viasuch a cable. Alternatively and/or additionally, the in-ear audio device100 may receive such audio through a wireless coupling with anotherdevice.

FIGS. 2a and 2b, taken together, provide two views of another embodimentof the in-ear audio device 100 that additionally incorporates an outerportion 130 meant to be positioned alongside the pinna of a user's earduring operation, and a support portion 140 to engage a portion of thepinna during operation. More specifically, the outer portion 130 has anelongate shape with one end coupled to the concha portion 120 in amanner that positions the outer portion 130 just outside the pinna, andthe other end extending therefrom and alongside the pinna towards theuser's mouth. To the one end of the outer portion 130 that is coupled tothe concha portion 120 may also be coupled a support portion 140 engagea portion of the pinna as an aid to securing the in-ear audio device 100in place relative to the user's ear during operation. Disposed on theother end of the outer portion 130 that extends towards the users mouthis a communications microphone 160 to detect speech sounds of the userfrom the vicinity of the user's mouth.

The embodiment of in-ear audio device 100 depicted in FIGS. 2a-b may beany of a variety of types of in-ear audio device able to perform 2-waycommunications (e.g., a wireless headset or “earset” for use with a cellphone). This variant of in-ear audio device 100 may also provide ANRand/or may wirelessly receive entertainment audio from an audio device(e.g., the same cell phone used in two-way communications, or a digitalaudio player).

FIGS. 3a and 3b show partially cut-away views of two different variantsof the in-ear audio device 100 of FIGS. 1a-b at least partially preparedfor customization of fit into a portion of a user's ear. Morespecifically, the variant depicted in FIG. 3a has been prepared forcustomization of fit into a portion of the ear canal of the user's ear,and the variant in FIG. 3b has been prepared for customization of fitinto a portion of the concha of the user's ear. Both of these depictedvariants have a physical configuration generally similar to what wasdepicted in FIGS. 1a and 1b.

As depicted, the casings of both variants incorporate the canal portion110 and the concha portion 120. Other possible variants (not depicted incut-away views) may further include the outer portion 130. Further, bothvariants incorporate circuitry 180 and an acoustic driver 190 that iselectrically coupled to the circuitry 180. Within the canal portion 110,a channel 116 is formed that extends from the aperture 118 through to anopen interior portion 125 of the concha portion 120. Within the conchaportion 120, the open interior portion 125 is separated by wallstructure and the acoustic driver 190 from another open interior portion126 in which the circuitry 180 is depicted as being disposed (though itshould be noted that the circuitry 180 may be disposed in any of avariety of locations either within the casing of the in-ear audio device100, or externally thereof).

The casings of both variants further incorporate one or more bags 150 tobe expanded through injecting moldable material via one or more tubes255 to cause the one or more bags 150 to expand into a portion of theuser's ear as part of the process of customizing the fit into the user'sear, as will be explained in greater detail. An important differencebetween these two depicted variants is that the variant of FIG. 3a hasan annular form of one bag 150 extending around the canal portion 110,while the variant of FIG. 3b has one or more bags 150 extending aboutthe concha portion 120. Thus, the variant of FIG. 3a is prepared for thefit of the canal portion 110 within the ear canal of the user's ear tobe customized, while the variant of FIG. 3b is prepared for the fit ofthe concha portion 120 within the concha of the user's ear to becustomized. It should be noted that these are but two examples of themanner in which the fit of variants of the in-ear audio device 100 inthe ear of a user may be customized. For example, although notspecifically depicted, a variant is possible in which one or more bags150 are disposed on portions of both the canal portion 110 and theconcha portion 120 to enable the fit in both the ear canal and theconcha of a user's ear to be customized.

There are two goals meant to be achieved in customizing the fit ofeither of these variants (or of still other variants) of the in-earaudio device 100 within an ear. First, is to provide a fit that is snugenough that the in-ear audio device 100 (whatever the variant) cannotsimply fall out of a user's ear. Second, is to provide a close enoughfit between a portion of the casing of the in-ear audio device 100 and aportion of a user's ear to enable a seal to be reliably formedtherebetween that acoustically separates the environment within the earcanal from the external environment each time the user inserts thein-ear audio device 100 into their ear. As those skilled in the art ofacoustics will readily recognize, with an entrance to the ear canalbeing formed of pliable skin, muscle and other tissues, the degree ofsealing from the external environment actually alters the acousticresponse of the ear canal to sounds acoustically output by the acousticdriver 190. Thus, it is desired to achieve a degree of fit that willenable a good degree of sealing to be achieved each time the userinserts the in-ear audio device into the ear for which the fit wascustomized. Enabling a seal to be reliably and repeatably formed eachtime the user inserts the in-ear audio device 100 into their ear enablesa predictable degree of quality of frequency response of the acousticdriver 190 acoustically outputting audio into the ear canal, and thisenables more consistent provision of higher quality sound into the earcanal, more consistent detection of the user's voice from within the ear(in variants supporting two-way communications through detecting theuser's voice through the user's ear), and more consistent provision ofANR (e.g., enabling provision of feedback-based ANR with reducedlikelihood of instability). In particular, the formation of such a sealenables the acoustic driver 190 to more efficiently acoustically outputlower frequency (bass) sounds, which aids both in providing higherfidelity acoustic output of entertainment and voice audio, and inproviding ANR.

Both of the variants of FIGS. 3a and 3b, in being prepared forcustomizing the fit of each into an ear of a user, are provided with amicrophone that is acoustically coupled to the channel 116 for use inadjusting the customized fit, as will be explained in greater detail.However, while the microphone employed in customizing the fit of thevariant of FIG. 3a is an instrument microphone acoustically coupled to atube 275 that is inserted through apertures 128 formed through portionsof the concha portion 120 so that the tube 275 opens into the channel116, the microphone employed in customizing the fit of the variant ofFIG. 3b is a built-in microphone 170 disposed within the channel 116and/or the open interior portion 125 and electrically coupled to thecircuitry 180. This is another important difference between these twovariants. The variant of FIG. 3a normally has no microphone disposedwithin its casing, and may be a form of the in-ear audio device 100 thatonly acoustically outputs audio received by the circuitry 180 fromanother audio device serving as a source of audio and coupled to thisform of the in-ear audio device 100 via a wireless link (through areceiver or transceiver of the circuitry 180) or via some form ofelectrically or optically conductive cable (not shown) that is coupledto the circuitry 180. In contrast, the variant of FIG. 3b incorporatesthe built-in microphone 170, and may be a form of the in-ear audiodevice 100 that supports two-way communications in which the built-inmicrophone 170 is employed to detect the user's speech sounds fromwithin the ear canal or may be a form of the in-ear audio device 100that provides feedback-based ANR in which the built-in microphone 170 isemployed to detect noise sounds within the ear canal as feedbackreference noise sounds from which feedback anti-noise sounds arederived.

Both of the variants of FIGS. 3a and 3b are depicted as having at leastthe aperture 128 formed between the open interior portion 126 and theenvironment external to a user's ear. It may be that the apertures 128in the variant of FIG. 3a are solely for the purpose of enabling theinsertion of the tube 275 of an instrument microphone through portionsof the concha portion 120 and into the channel 116 within the canalportion 110 (and preferably, such multiple apertures 128 are aligned tomake the insertion of the tube 275 easier). However, in both variants,one or more of the apertures 128 may serve as acoustic ports to in someway tune the frequency response of the acoustic driver 190 and/or mayserve to enable equalization of air pressure between the ear canal andthe external environment. Specifically, such ones of the apertures 128may have dimensions and/or other physical characteristics selected toacoustically couple one or open portions within the casing of the in-earaudio device 100 to each other and/or to the external environment withina selected range of frequencies. Further, one or more damping elements(not shown) may be disposed within one or more of such ones of theapertures 128 to cooperate with characteristics of the acoustic driver190 to alter frequency response.

Additionally or alternatively, one or more of the apertures 128 may beformed in the concha portion 120 (and/or in other portions of thecasing) to provide a controlled acoustic leak between the ear canal andthe external environmental for purposes of controlling the effects ofvariations in fit that may develop over time after customization hasbeen performed and an initial fit bringing about a desired quality ofacoustic response has been achieved. As will be recognized by thoseskilled in the art, variations in the health or other aspects of thephysical condition of a user can bring about minor alterations in thedimensions and/or shape of the ear canal over time such that the qualityof the seal able to be formed with each insertion of the in-ear audiodevice 100 into the ear over time may degrade. Thus, in someembodiments, the dimensions and/or other characteristics of one or moreapertures 128 formed in the casing may be selected to aid in mitigatingthe effects of a slightly degraded quality of seal by providing apre-existing leak of controlled characteristics that mitigates theacoustic effects of other leaks developing in the future in the sealbetween the casing of the in-ear audio device 100 and portions of theear. For example, the dimensions of one or more apertures 128 may beselected to be large enough to provide a far greater coupling betweenthe ear canal and the external environment than any other couplingthrough a leak in the seal that may develop at a later time.

FIG. 4 provides a block diagram of a customizing system 200 by which theprocess of customizing the fit of the in-ear audio device 100 within anear of a user is performed and controlled. It is contemplated that thecustomizing system 200 would be operated by an operator with some amountof training in aspects of customizing the fit of the in-ear audio device100, perhaps a nurse or other type of technician at a clinic. However,it is certainly possible that the customizing system 200 could be madeeasy enough to use as to make it reasonable for a would-be user of thein-ear audio device 100 to operate it to customize the fit within one oftheir own ears.

The customizing system 200 incorporates a source of filling material250, a filling control 252 and a pressure sensor 253, all coupled tocontrollably provide an amount of the filling material 250 to one ormore bags 150 formed on the canal portion 110 and/or the concha portion120 of the casing of the in-ear audio device 100 through one or moretubes 255 coupled to those one or more bags 150. The customizing system200 also incorporates a user interface 230 including one or more audibleand/or visible indicators (e.g., buzzers, status lights, LCD display,etc.) and manually-operable controls (e.g., manually-operable switches,keyboard, etc.) to allow manual control of at least some aspects ofcustomization of fit, a storage 220 in which is stored a control routine225, and a processing device 210 coupled to the storage 220 to accessand execute a sequence of instructions of the control routine 225. Theprocessing device 210 is also coupled to the filling control 252 tooperate the filling control 252 to effect the filling of one or more ofthe bags 150 through one or more of the tubes 255 to a controlledextent, and is further coupled to the pressure sensor 253 to monitor thepressure created in the tube 255 during customization. The customizingsystem 200 also incorporates at least an earpiece interface 290 toenable coupling of the customization system 200 (with either a wired orwireless coupling) to the circuitry 180 of the in-ear audio device 100to at least cause the acoustic driver 190 to be driven to acousticallyoutput various test sounds during customization. The customizing system200 may further incorporate the instrument microphone 270, at leastwhere the instrument microphone 270 is to be used in monitoring theacoustic results of the acoustic output of the test sounds, instead ofthe built-in microphone 170 in variants of the in-ear audio device 100that incorporate the built-in microphone 170 (e.g., the variant of FIG.3b). Where such a built-in microphone as the built-in microphone 170 isemployed, the earpiece interface 290 may be further employed to use itscoupling to the circuitry 180 to enable monitoring of the built-inmicrophone 170.

In essence, an embodiment of performing a customization of fit entailsinserting one of the in-ear audio devices 100 with one or more of thebags 150 initially in a collapsed state into an ear of a would-be userof that in-ear audio device 100, and then filling the one or more of thebags 150 with a slowly increasing amount of the filling material 250while the acoustic driver 190 is driven to acoustically output varioustest sounds (perhaps continuously or perhaps at intervals), while amicrophone (either the built-in microphone 170 or the instrumentmicrophone 270) is used to monitor the acoustic results of the acousticoutput of those test sounds, and while the pressure sensor 253 ismonitored to avoid filling the one or more bags 150 with the fillingmaterial 250 at a pressure outside an expected range. The fillingcontinues until whatever microphone is employed detects sounds withcharacteristics indicating a desired degree of sealing has beenachieved, until the would-be user indicates (perhaps through the userinterface 230) that the fit resulting from the filling of the one ormore bags 150 is becoming uncomfortable, or until the pressure sensor253 detects a pressure outside a predetermined range of pressures thatare expected to be encountered during customization. It may be thatafter the filling is done some small amount of the filling material 250is then withdrawn from the one or more bags 150 to achieve a degree offilling of the one or more bags 150 that is found to provide the desireddegree of sealing. The filling material 250 is then allowed to cure or“set up” such that it ceases to be in the liquid form that enabledfilling through one or more of the tubes 255, and becomes more solid sothat the one or more bags 150 permanently hold a shape that iscustomized to that user's ear (though preferably still soft to somedesired degree that provides some degree of comfort).

Turning to some of the internal details of carrying out customization,it is through accessing the storage 220 to retrieve and execute asequence of instructions of the control routine 225 that the processingdevice 210 is caused to control customization. First, the processingdevice 210 awaits input via the user interface 230 that the in-ear audiodevice 100 has been properly positioned within an ear of the would-beuser, and that the one or more tubes 255 needed to fill one or more bags150 of the in-ear audio device 100 are in place such that customizationcan be performed. The processing device 210 then operates the earpieceinterface 290 to convey test sounds to the circuitry 180 of the in-earaudio device 100 to cause the acoustic driver 190 therein to output testsounds. The processing device 210 also either monitors the instrumentmicrophone 270 or further operates the earpiece interface 290 to obtainto monitor the built-in microphone 170 through the circuitry 180(depending on which of these two microphones is employed incustomization) to monitor the acoustic results of the acoustic output ofthe test sounds by the acoustic driver 190. While causing the testsounds to be acoustically output and monitoring the results of doing so,the processing device 210 further operates the filling control 252 tobegin filling the one or more bags 150 of the in-ear audio device 100with the filling material 250 through the one or more tubes 255employed, and the processing device 210 also monitors the pressuresensor 253 for indications of a pressure level outside a range ofpressures expected to be detected during customization.

Preferably, the processing device 210 is caused by execution of thecontrol routine 255 to simply continue causing the acoustic output oftest sounds, continue monitoring the acoustic results through whichevermicrophone is employed, and continue filling the one or more bags 150with the filling material 250 until the characteristics of the soundsdetected by that microphone indicate that a seal has been achievedbetween the in-ear audio device and the ear that the ear canal issufficiently acoustically separated from the external environment that adesired quality of acoustic response to the acoustic output of theacoustic driver 190 has been achieved. Upon receiving this indication,the processing device 210 operates the filling control 252 to ceasefilling the one or more bags 150 with the filling material 250.

Although it is preferred that the customizing of fit be carried outunder the control of the processing device 210 as directed through itsexecution of the control routine 225, it may still be desired to providesome visual or other indication through the user interface 230 ofconditions during and/or following customization, perhaps to enable somedegree of “fine tuning” of the fit by an operator. More specifically,the user interface 230 may be operable by the processing device toprovide an operator with a visual display or other indication of theselection of test sounds being employed by the processing device 210,the frequency response of the ear canal to the acoustic output of thosetest sounds by the acoustic driver 190 of the in-ear audio device 100,and of the pressure at which the filling material 250 is provided to theone or more bags 150. The provision of such information would enable anoperator to perhaps guide the choice of test sounds and/or the pressureat which filling is done. While the processing device 210 may accesssome amount of control data 226 stored in the storage 220 to obtain dataconcerning frequency response characteristics of known instances of agood seal resulting in a desirable degree of frequency response beingachieved as a reference against which to compare frequency responsecharacteristics observed during a current customization. The controldata 226 may further include statistical and/or predictive analysisalgorithms to be employed by the processing device 210 in iteratingthrough testing differing degrees of filling the one or more bags 150with different test sounds as part of achieving a degree of filling ofthe one or more bags 150 that achieves a fit that enables a desiredquality of frequency response.

It is desired that the filling occur without a level of pressure beingdetected by the pressure sensor 253 that is either lower than expectedsuch that it may be an indication of a leakage of the filling material250, or that is higher than expected such that it may be an indicationof a blockage in a tube 255 such that filling material 250 is not beingconveyed through that tube 255. A maximum pressure level may also beselected that the processing device 210 does not allow to be exceeded asa safety feature to avoid injury to would-be users. In response to thedetection of a level of pressure outside the expected range, theprocessing device 210 may be caused by the control routine 225 toimmediately operate the filling control 252 to cease conveying any moreof the filling material 250 into the one or more tubes 255 being used,and may further operate the filling control 252 to withdraw at leastsome of the filling material 250 previously conveyed into the one ormore tubes 255 being used. Further, the user interface 130 may beoperable by the processing device 210 to provide a visual or audiblealert of the anomalous pressure level that has been detected.

It is also desired that customization be completed without the userinterface 230 needing to be operated by someone to manually intercede inthe customizing, perhaps due to the would-be user indicating that theone or more bags 150 have been filled to a point that the fit isuncomfortable. However, with the high degree of variability inphysiology of ears between different people, it may be that a particularwould-be user of the in-ear audio device 100 is all too sensitive to thesensation of having the one or more bags 150 being filled to the extentthat enough of a seal is created that the desired quality of frequencyresponse is achieved, and thus, a somewhat lesser quality of frequencyresponse may have to be accepted. To accommodate this possibility, itmay be that the user interface 230 includes a manually-operablecontrolled that is provided to the would-be user of the in-ear audiodevice 100 during customization that allows them to immediately stop thefilling of the one or more bags 150 upon beginning to feel someundesirable amount of discomfort. The user interface 230 may be operableby the processing device 210 to provide a visual display of aspects ofthe frequency response achieved thus far in that customization to allowan operator of the customizing system 200 to determine if a less thandesired quality of frequency response is still good enough. Yet further,the user interface 130 may be operable to provide a visual display ofthe pressure under which the filling material 250, which may providesome insight to an operator of the customizing system 200 as to whetherenough of a snug fit has yet been achieved to prevent the in-ear audiodevice 100 from falling out of the would-be user's ear. If the would-beuser suffers from some physiological or neurological condition thatprecludes even filling the one or more bags of the in-ear audio device100 with enough filling material 250 to achieve even a fit that willprevent the in-ear audio device 100 from falling out, then it may not bepossible to customize the fit for that ear of that particular would-beuser.

In some embodiments, the test sounds are made up of a wide range offrequencies of human audible sounds (e.g., 20 Hz to 20 KHz). Such a widerange of frequencies may be covered with an acoustic output of soundsthat sweep continuously from one end of the range of frequencies toanother, or that step through a number of distinct frequencies selectedthroughout the range of frequencies, or in some other manner. Such awide spectrum of frequencies may be further employed to develop anequalization curve to be programmed into the circuitry 180 to furtherenhance the quality of sound experienced by the would-be user as thelisten to audio output by the acoustic driver 190 during normal use ofthe in-ear audio device 100 after customization has been done.Alternatively or additionally, such an equalization curve may beprogrammed into an audio source device (e.g., a radio) that providesaudio to the circuitry 180 for being acoustically output by the acousticdriver 190. Indeed, where a broad range of frequencies of sounds is tobe used, a carefully selected piece of music with the desired range offrequencies of sounds may be used.

Alternatively, in other embodiments, the test sounds are made up oflower frequency sounds (e.g., approximately 50-300 Hz). Such frequenciesmay be chosen to correspond to dimensions and/or other physicalcharacteristics that are selected and given to one or more of theapertures 128 (however many there may be in a given embodiment) toacoustically couple the ear canal to the external environment withinthose lower frequencies, possibly to enhance the effectiveness of thosetest sounds in evaluating frequency response. However, such lowerfrequency sounds may still be supplemented with a range of higherfrequency sounds employed to test for possible resonances acousticresonances within an ear canal.

In some embodiments, the casing of the in-ear audio device 100 may beseparable into multiple pieces, either to allow for some greaterflexibility in customization or to allow a previously customized portionof the casing of one in-ear audio device 100 to be separated and usedwith another. For example, there may be a selection of canal portions110 from which a particular canal portion 100 may be selected toaccommodate a particular size of ear canal of a particular would-beuser. Correspondingly, there may be a selection of concha portions 120from which a particular concha portion 120 may be selected toaccommodate a particular size of concha of a particular would-be user.Also for example, either a single bag 150 or a set of the bags 150 maybe separable from other casing portions to enable their reuse with othercasing portions of a replacement or upgraded form of in-ear audio device100 (perhaps some newer version that adds ANR, has a higher qualityacoustic driver, or provides some other audio feature) to allow a fitpreviously achieved using that one or more bags 150 to be carried overas a user of one in-ear audio device 100 makes a switch to another one.

Indeed, a mixing and matching of different casing portions may precedethe customization of fit as a way of first achieving a “rough” fitbefore employing one or more of the bags 150 in customization to achievea still better fit. The use of different ones of a selection of thecanal portion 110 and/or the concha portion 120 (and/or still othercasing portions) can change the test sounds that are best used and/orthe characteristics of the frequency response sought to be achievedduring customization. For example, different sizes of the canal portion110 can bring about different lengths and/or diameters of the channel116 and/or different dimensions of the aperture 118 into the ear canalsuch that the acoustics of the canal portion 110 are sufficientlydifferent among different sizes of the canal portion 110 that a singleset of test sounds are not effective for use among all of the differentsizes.

It may be that some form of memory device or other type of data storageis carried within the in-ear audio device 100 (possibly within thecircuitry 180) that stores information concerning its customization fora particular user, such as characteristics of the test sounds used(e.g., types of sounds, frequencies used), characteristics of thefilling material 250 (e.g., its composition, viscosity, pressure, volumeused), characteristics of one or more portions of the casing (e.g.,dimensions of one or the other of the canal portion 110 and conchaportion 120). This may be of use in speeding subsequent customizationsof future in-ear audio devices 100 for use by the same user, perhapsavoiding the need to again deduce what sizes of casing portions shouldbe selected or what test sounds are best used for a particular ear. Suchinformation may additionally or alternatively be maintained by a server(not shown) that perhaps stores sets of such information over time asnew customizations for a particular user are done over time—perhapsenabling trends concerning characteristics of a particular user's ear(s)to be derived that may be useful to future customizations.

In yet other alternative embodiments, it may be that no microphone isemployed in monitoring the acoustic results of the acoustic output oftest sounds to determine when a desired quality of frequency responsehas been achieved. Instead, the impedance and/or other characteristicsof the acoustic driver 190, itself, may be monitored to detect aninstance of the acoustic driver 190 having an impedance or othercharacteristic during acoustic output of a sound of a known frequencythat is indicative of a desirable quality of frequency response beingachieved.

It should be noted that although customization has been presented hereinas a process carried out time to achieve a fit for a given in-ear audiodevice, embodiments of an in-ear audio device are possible in which thein-ear audio device maintains a reservoir of filling material that doesnot cure and that is employed in performing a customization every timeit is put into a user's ear.

Other implementations are within the scope of the following claims andother claims to which the applicant may be entitled.

The invention claimed is:
 1. A method of customizing the fit of aportion of a casing of an in-ear audio device within a portion of anear, the method comprising: driving an acoustic driver of the in-earaudio device to acoustically output a test sound into the ear canal ofthe ear; monitoring a microphone that is acoustically coupled to the earcanal to detect sounds within the ear canal that are indicative of thefrequency response of the acoustic driver acoustically outputting thetest sound into the ear canal; filling a bag of the casing with afilling material as the acoustic driver is driven to acoustically outputthe test sound and the microphone is monitored; and employing the soundsdetected by the microphone that are indicative of the frequency responseof the acoustic driver acoustically outputting the test sound into theear canal to determine if a degree of sealing between the portion of thecasing and the portion of the ear achieves a desired quality offrequency response of the acoustic driver acoustically outputting thetest sound.
 2. The method of claim 1, wherein the test sound comprises awide range of frequencies of human audible sounds.
 3. The method ofclaim 1, wherein the test sound is at a lower human audible frequency.4. The method of claim 3, wherein the casing comprises at least oneaperture that acoustically couples the ear canal to an externalenvironment that is external to the casing at the lower human audiblefrequency.
 5. The method of claim 1, wherein monitoring the microphonecomprises monitoring a built-in microphone disposed within the casing ofthe in-ear audio device.
 6. The method of claim 1, wherein: themicrophone is an instrument microphone comprising a tube; and the methodfurther comprises inserting the tube of an instrument microphone throughan aperture formed in the casing to acoustically couple the instrumentmicrophone to the ear canal through the tube to enable detecting thesounds within the ear canal that are indicative of frequency response.7. The method of claim 1, wherein: filling the bag with the fillingmaterial comprises filling the bag with the filling material in a liquidstate before the filling material cures; and the method furthercomprises waiting for the filling material to cure within the bag beforeremoving the in-ear audio device from the ear.
 8. The method of claim 1,further comprising: monitoring the level of pressure with which thefilling material is conveyed to the bag to fill the bag; and ceasing toconvey the filling material to the bag in response to the level ofpressure being outside a predetermined range of pressure levels expectedto be detected during filling of the bag.
 9. The method of claim 1,further comprising: monitoring a manually-operable control for anindication of the degree of filling of the bag causing discomfort to awould-be user of the in-ear audio device to whom the ear belongs; andceasing to convey the filling material to the bag in response to theindication.
 10. An apparatus comprising: a filling control tocontrollably convey filling material into a first tube structured to becoupled to a bag of a casing of an in-ear audio device; an earpieceinterface to at least signal the in-ear audio device with a test soundto be acoustically output by an acoustic driver disposed within thecasing of the in-ear audio device; a processing device; and a storagestoring a sequence of instructions that when executed by the processingdevice causes the processing device to: operate the earpiece interfaceto cause the acoustic driver to acoustically output the test sound intoan ear canal of an ear; monitor a microphone that is acousticallycoupled to the ear canal to detect sounds within the ear canal that areindicative of the frequency response of the acoustic driver acousticallyoutputting the test sound into the ear canal; operate the fillingcontrol to fill the bag with the filling material as the acoustic driveris driven to acoustically output the test sound and the microphone ismonitored; and employ the sounds detected by the microphone that areindicative of the frequency response of the acoustic driver acousticallyoutputting the test sound into the ear canal to determine if a degree ofsealing between the portion of the casing and the portion of the earachieves a desired quality of frequency response of the acoustic driveracoustically outputting the test sound.
 11. The apparatus of claim 10,wherein the test sound comprises a wide range of frequencies of humanaudible sounds.
 12. The apparatus of claim 10, wherein the test sound isat a lower human audible frequency.
 13. The apparatus of claim 12,wherein the casing comprises at least one aperture that acousticallycouples the ear canal to an external environment that is external to thecasing at the lower human audible frequency.
 14. The apparatus of claim10, wherein the microphone comprises a built-in microphone disposedwithin the casing of the in-ear audio device.
 15. The apparatus of claim10, further comprising the microphone, wherein the microphone is aninstrument microphone comprising a tube to be inserted through anaperture formed in the casing to acoustically couple the instrumentmicrophone to the ear canal through the tube to enable detecting thesounds within the ear canal that are indicative of frequency response.16. The apparatus of claim 10, further comprising a pressure sensor,wherein the processing device is further caused to: monitor the level ofpressure with which the filling material is conveyed to the bag to fillthe bag; and cease conveying the filling material to the bag in responseto the level of pressure being outside a predetermined range of pressurelevels expected to be detected during filling of the bag.
 17. Theapparatus of claim 10, further comprising a user interface comprising amanually-operable control, wherein the processing device is furthercaused to: monitor the manually-operable control for an indication ofthe manually-operable control being operated to cause the filling of thebag to stop due to discomfort of a would-be user of the in-ear audiodevice to whom the ear belongs; and cease conveying the filling materialto the bag in response to the indication.
 18. A method of characterizingthe fit of a portion of a casing of an in-ear audio device within aportion of an ear, the method comprising: driving an acoustic driver ofthe in-ear audio device to acoustically output a test sound into the earcanal of the ear; monitoring a microphone that is acoustically coupledto the ear canal to detect sounds within the ear canal that areindicative of the frequency response of the acoustic driver acousticallyoutputting the test sound into the ear canal; and employing the soundsdetected by the microphone that are indicative of the frequency responseof the acoustic driver acoustically outputting the test sound into theear canal to determine if a degree of sealing between the portion of thecasing and the portion of the ear achieves a desired quality offrequency response of the acoustic driver acoustically outputting thetest sound, wherein the test sound comprises a wide range of frequenciesof human audible sounds.
 19. The method of claim 18, wherein the casingcomprises at least one aperture that acoustically couples the ear canalto an external environment that is external to the casing.
 20. Themethod of claim 18, wherein monitoring the microphone comprisesmonitoring a built-in microphone disposed within the casing of thein-ear audio device.
 21. The method of claim 18, wherein the test soundcomprises music.
 22. The method of claim 18, wherein the in-ear audiodevice is an active noise reduction (ANR) device.
 23. The method ofclaim 18, further comprising outputting a visual indication through auser interface associated with the in-ear audio device of the frequencyresponse of the acoustic driver acoustically outputting the test soundinto the ear canal.
 24. The method of claim 18, wherein the test soundis one of a plurality of test sounds, and further comprising outputtinga visual indication through a user interface associated with the in-earaudio device of the plurality of test sounds.
 25. The method of claim18, further comprising comparing the frequency response to datacomprising frequency response characteristics indicative of a sufficientseal.
 26. The method of claim 18, further comprising selecting thecasing from one of a plurality of different sized casings.
 27. An in-earaudio device comprising: an earpiece interface to at least signal thein-ear audio device with a test sound to be acoustically output by anacoustic driver disposed within a casing of the in-ear audio device; aprocessing device; and a storage storing a sequence of instructions thatwhen executed by the processing device causes the processing device to:operate the earpiece interface to cause the acoustic driver toacoustically output the test sound into an ear canal of an ear; monitora microphone that is acoustically coupled to the ear canal to detectsounds within the ear canal that are indicative of the frequencyresponse of the acoustic driver acoustically outputting the test soundinto the ear canal; and employ the sounds detected by the microphonethat are indicative of the frequency response of the acoustic driveracoustically outputting the test sound into the ear canal to determineif a degree of sealing between the portion of the casing and the portionof the ear achieves a desired quality of frequency response of theacoustic driver acoustically outputting the test sound, wherein the testsound comprises a wide range of frequencies of human audible sounds. 28.The in-ear audio device of claim 27, wherein the casing comprises atleast one aperture that acoustically couples the ear canal to anexternal environment that is external to the casing.
 29. The in-earaudio device of claim 27, wherein the microphone comprises a built-inmicrophone disposed within the casing of the in-ear audio device. 30.The in-ear audio device of claim 27, wherein the in-ear audio device isan active noise reduction (ANR) device.
 31. The in-ear audio device ofclaim 27, further comprising a user interface associated with the in-earaudio device, and wherein the processor is further configured to outputa visual indication on the user interface of the frequency response ofthe acoustic driver acoustically outputting the test sound into the earcanal.
 32. The in-ear audio device of claim 27, wherein the test soundis one of a plurality of test sounds, and further comprising a userinterface associated with the in-ear audio device, wherein the processoris further configured to output a visual indication on the userinterface of the plurality of test sounds.
 33. The in-ear audio deviceof claim 27, wherein the processor is further configured to compare thefrequency response to data comprising frequency response characteristicsindicative of a sufficient seal.
 34. The in-ear audio device of claim27, wherein the casing is selected from one of a plurality of differentsized casings.
 35. The in-ear audio device of claim 27, wherein the testsound comprises music.